Process of converting hydrocarbons



Feb, 7, 1939- H. v. ATWELL PROCESS OF CONVERTING HYDROCARBON'S Filed May 23, 1936 mm v lNVENTOR HhRoLoVHTweLL JQ H-. ATTORNEY Patented Feb. '1', 1939 ';rnoonss oroosvaamo mznmocaanons may. .Amu, Whitellains, N; 1., assignor to Process Management Company, Inc., New

York. lY.'Y., a of Application m y 23, 936, Serial 1v. sis-16 -s c1uma (o1. 196-16) This inventionirelates to the treatmentofihydrocarbons and particularlyto thecatalytic poly-- ous hydrocarbons merization of normally containing oleiinic constituents.

5 In the catalytic polymerization of unsaturated hydrocarbons, it is customary to pass the heated gases through a stationary bed of solid catalytic material. Among thefe'atures, of importance ,to observe in processes of thistypelare the maintenance. of an even distribution throug h the bed of catalytic material and only a reasonablepressure drop through the bed. Wconsequently the, catalytic contact surface presented to flowing gases can not be increased as much as might be desired by ,subdivi ding the catalyst without encountering' difl 'iculties with respect to the abovementioned features. Such processesusing a stationary catalyst also present a diflicult problem of temperature control since considerable quantities of heat of exothermicpoLvmerization must be dissipated.

One of the objects or this invention is to provide a process for catalytically polymerizing-hr, drocarbon gases containing unsaturates wherein" a relatively large and active catalytic surface is moval of catalysts together with strictly counter-6 utilized. I y 7 v Another object of my invention is to provide a process of: the character mentioned wherein countercurrent contact between thecatalysts and the gases being-polymerized is effected throughout the entire catalytic reaction. 5 I

Still another'object of my invention is to provide a process. of the character mentioned where-.

in the catalyst is admixed with a. liquid vehicle to facilitate the countercurrentflow ofthe vehi'ciefc'arrying the catalyst and the" hydrocarbon gases'bing polymerized. Another object of my invention is to.provide a process of the character mentioned whereina,

40 relatively volatile liquid is utilized, at least in part, asthe fluid vehicle for the catalytic material.

With these and other "objects inlview, the 111-,

vention comprises the improvements hereinafter 4 5 setforth and claimed,- withv the understanding that the procedure may be varied without de- I partingfrom the spirit and scope of the appended claims.

My invention contemplates processing oleflnic 50 gases'from any suitable source, such as'from oil cracking operations or from operations wherein natural gas or refinery gas is. 'dehydrogenated. Gases of this character are'suitably heated to a 6 temperature of from 200 to 500 1''; preferably 66 to a temperature of about'30 l"; while being maintained at atmospheric pressure or elevated 'pressureaperhaps as high as 1000 'lbs., and i2: passed to a reaction zone, such as a suitably packed tower, wherein the unsaturated consti-tu-w. ,ents of the gases, includingl the more diihcultly 5-.

polymerizable ethylene, are-contacted with a gpolymerization catalyst. The tower receiving the.

heatedhydrocarbongases is preferablylprovided" with suitable packing material, such as Raschig rings, finely divided brick or any other suitable .102

material. Atower, such as a bubble tower; ca-

.pable of maintaining distinct pools of liquids w ,while permitting continuous countercurrent flow-,-..

may also be used.

In order to provide a relatively, larg 55am surface for the upwardly rising gases: n their; 5

tower,-my invention contemplates introducing ;a

7 suitable catalyst suspended and/or dissolved'in a liquid vehicle into an upper portion of thetowen to accomplish countercurrent flow. between thee-20 6:: 4 liquid vehiclaand catalyst and the upwardly ing gases. Y

:The advantages of having the catalyst influid f form are of paramount importance. In the first,

place, itpermits continuous introduction. and re-.-I'25 current. operation, both of whichfeatures greatly increase the efllcienc'y of the process. the 2.-

secondplaoe, it minimizesthe possibility'ofzchan-.1

neling which is a constant source of trouble -in1-80ug operations wherein a bed of granular-material is used-and insures that all of the gas being ,w: polymerized will come ,into intimate and. direct contact with catalytic surfacesof equal activity, 7

thereby exhausting all of the catalytic material 35] at the same rate.

I chloride, aluminum chloride, alumina on silica,;40 [fuller's earth or clay, and others, ,allof which 1 are preferably in finely divided state, maybe formed with a suitable liquid vehicle. I may use as the vehicle for the finely divided catalytic 6 material, compounds of hydrocarbonsthat are not volatilized by the prevailing temperature, such as propylene glycol and other polyhydric alcohols, I" I high-boiling monohydric alcohols, nitro paramns, A

halogenated derivatives of, olefins and paraillns, etc. The choice of a vehicle depends largely on its boiling point with respect to the desired operating temperature and its inertness with respect to the catalyst used. Whenhalide catalysts such as aluminum chloride are used,.par-v ticularly good results are obtained by using a For instance, a

halogen compound as a vehicle. For example, a chlorinated octane or nonane may be used as the vehicle for sodium aluminum chloride. For a more active catalyst, aluminum chloride, which .5 would be used at a lower temperature, a lower boiling vehicle, such as ethylene dichloride. would ;be preferred.

My invention also contemplates the additionoi a volatile oil to the catalyst suspension and/or solution for passage through the treating-tower counter-current to the upwardly rising vapors. I'he volatile oil included in the catalyst iiuid is readily vaporized and this vaporization serves ,to absorb the heat of polymerization'andthus control the temperature'inthe tower. By conducting the polymerization in a tower using countercurrent flow, the temperature-controlling volatile oil is carried downwardly until it has absorbed suificient heat to be vaporized and, therefore, -20 gives automatic temperature control at all parts of the system. This volatile oil is in general unaflected by the catalyst present in the liquid vehicle and may be a polymer fraction produced in the-system, kerosene, or a relativelynarrow frac- 26 tion of straight run gasoline, or pure hydrocarbons of the desired boiling point. Optionally the catalyst vehicle itself may be selected to have 9.

boiling point suitable for controlling the temperature in the system by self-evaporation. In any 80 case, cooling'will be provided at the top of the tower, either by indirect heat exchange to condense the escaping vapors, br'by the continuous introduction of the volatile cooling medium re: covered by extraneous condensation. 35 My invention makes possible more ready polymerization of ethylene which, as has been generally recognized, is diflicult to polymerize catalyticallyunder the conditions suitable for other gaseous oleflns. In accordance with this specific aspect of my invention, ethyleneis polymerized by passing it through a body or in countercurrentv contact with a flowing stream of a metallic halide type of catalyst such as sodium aluminum chloride or any other suitable catalyst suspended character heretofore mentioned. By thus employing a liquid hydrecarbon as a vehicle iorthe catalyst, a greatly increased catalytic surface is provided which facilitates the polymerization of the ethylene.

For a further explanation of my invention, I-

perature between about 200 and 500 F., preferably about 300 F., while being maintained at about atmospheric pressure or higher. The heated gases leaving the heater 3 pass through a. line 4 toareactlon 'zone or tower 5', having suitable packing material 6 extending throughout, where in passage of the heated gases is effected through the spaces between the packing material. Catalytic material suspended and/or dissolved in a suitable liquid vehicle as aforementioned is introduced into the upper portion of the tower 5 and flows downwardly through the spacesbetween the packing material 6, thus intimately contacting the upwardly rising gases. A relatively largecatalytic surface is thus provided in the packed tower and/or dissolved in a hydrocarbon vehicle of the heater 3 wherein they may be heated to ateme,

amass? for the upwardly ifising gases, .and polymerization of the olefinic' 'constituents of these gasesfirito normally liquid hydrocarbons l is-effected.

W en u in a h d e arbonl q d wh ch is .sub-

stantially nomvol'atHe under the prevailing tern perature conditions as the liquidvehicle the catalyst suspension and/or solution continues to downwardly throughout the tower .5 withoutany substantial .chan'g'eiin its physical properties. As

such afluid mixture descends in the tower I the catalystgraduallyfbcomes exhausted and its cat} alytic properties are accordingly reduced. when a relatively volatileoil is mixed with the catalyst suspension and/or solution to function, at, least -in part, as an additional liquid vehicle, the tem- 'perature prevailingin the tower is generally cient to vaporize' all'or most of the volatileloil, which vaporizatlo'rieffects automatic temperature. control throughoutthe tower 5. When such a volatile oil is included in the catalyst suspension and/Or solutionfiit'is carried downwardly therewith until sumcieiit'heat has been vabsorbed to effect vaporizationtliereof. .By vaporization of the volatile oil, the heatof polymerization .15 transferred to the va x is thus removed from the system.

Polm'nerized material in vaporous form from the tower 5 as well'as vaporsof the cooling medium mixed with 'the catalyst suspensioni d/ solution. Dassthro'ugh a line 8 to .a'iractionating 5 by the catalytic i3 through a line forced by a pump I5 through a heater", wherein it is mildly heated to a temperature' of about 400 F. The thus mildly heated heavy polymer is passed through a-line 1-1 to the fractionating column 9 whereinit is mixed with the vaporous products entering the fractionator through the line 8. The products entering the'fractionator 9 are therein fractionated te condense out any heavy tarry material contained therein, this tarrypolymer being withdrawn from the system through a line 18; Fractionation v rithin the fractionator 9 is suitably controlled so that the overhead .vaporous fraction therefrom will consist mostly of hydrocarbons ithi the o 'fue boi in oi xr nse an lighter, this vaporous traction being withdrawn through a line .I 9 and passedthrough a condenser 2| and line 22 to 'a' disti late receiverlt. Uncon densed gases are withdrawn at least in irom the e r 23 hr ugh a ne .24 and the l q id c lq onta nmeemq r fu and g e is withdrawn through a line 25, having a valve",

and passed to a stabilizer 21 whieh may be.main]- t ed un e fs pera m snh ric p ssure by pum o sh wn. i e 1mm; "me u d t a rs-rising through thetower and V r ,4.0 polymerization may be withdrawn from an upper portion of the settlingtank :s'tituents: arerrenioved throughaakline ".therecibeing=withdrawn iroin*theeisys through" *a'line 'slandttheiremainderzreturne "tori ;he'-.u1:iper' rportion o'fith'e "stabilizer-through a lline 36 bywaj 1ipreierably;:provide:a zsuitablelcatalystjlmiiting iltzhaniber ill 11mm; a, stirring arrangement; com

' ax'shaft fl and'sstirrers ll .disposedonf-the shaft "to 2 accomplish edesirediagitation during the "formation of :the suspension fllId/QOI solution -.oi' :catalyst. sAny f-suitable =.catalyst, ;,:preie'rably i-in finely divided iiorm .may be introduced into the mixingechamberkll 'throul'zh-aLlinef. fl 'l eiliqiiid vehicle for lithe (catalyst 'simay :be directly Jintroduced into the chamber 54 l ithrougfh :8. line 145.

whilezitiis generaily des'ired1to iintroduce izires'h icatalys'ts through the line *into the mixing chamber n ,iathe.-s nt= catalysts aiand-liquid'vehicle I :may The zrevivifled :an'd recycled to :theiniixing chamber I l 5101' :reuse. "Thus the -sspent catalysts and zremainin'giliquid "vehicle .:may 'bemithdrawn Jirom'the sisettling zchamber ill throug'h ,a ;line 46 :and %passed into a :catalyst regeneratcr 1. The.

. 'rcatalys't :regenerator .is shown diagrammati- 5 cecallyi in that it forms no :part :or irny present :in-

'vention. .The'tthus 1 regenerated :catal'yst ,together iwithathe liquid" vehicle 5 is withdrawn Sirom the 5 re- ;zggenerator fllthrouglr alline and returned ibyl a :pump-fl to the mixingchaniber i ll n In :ffractionating the products in fraction- 1 ator l the kheavy traction-withdrawn throu h "the line I 8 generally .an undesired tarry material while .the -vaporous traction =withdrawn through the line [9 comprises aa .gasoline oi the desired I characteristics. In -accordancexwith, -my process,

'iiractionation "within the ttower may be aconx trolle'd so as toseparate a condensatekintermedi- "ate 1 the (gasoline-and: the tarry 1 material, having .a

"boiling point making it a suitable liqiiidfior ac- :complishingathe temperaturetcontrol before+mentioned? in ithe :tower 15 *or *fora-suspendingejand :clissolvingitheacatalyst.coriboth. iinte'rmediate condensatemay be withdrawniirom thejf t ractionzi'orced zbya pump: I I ithr'o'ughiai line 52 controlled iby ayalve' 53' toithe line liithroughxwhich the liq :uid vehiclel isintroducedinto themixing chamber.

n i all or "the intermediate :Jcondensa'te is not irequired .to from the desired :suspension and/or ,rsolution .iin "the mixing chamber 1 i for none .is :used for z-this :purpose, :a 1, part for all of this oil -.maybe'iorcedwthrough a line' ",having a valve 51, tola heaterltwherein itsisiheated nearlyto its boiling g-point. "The thus .mildly iheated intermediate condensate: is thenv 'passed through a line 58! :to the line "I through which the suspension and/or solution of catalyst an'd :liquid vehicle is z-introducediinto'zthe upper portion of the'rtower.

LFrom the .ioregoing 'it will be :evidenti that zby heating the intermediate condensate pass'iing through the1:heater' '58,' prior toadmixture z'thereso! with the catalyst suspension =and/or gasoline,

the .material entering "the tower l through the fline :1 will "be at ran elevated it emperature and will .not cdrasticall-y :cool ethe gases undergoing 1 polymerization. It will the understood that .oil

1 other than ;,the intermediate :condensate heretoi'ore described may be used ito accomplish the "temperature :control within the packed tower 6. When the operating conditions are: such that an intermediate'condensate of suitable boiling point I can not be obtainediconveniently from thezfractionator 9, the cooling oil maybe a relatively narrow boiling traction of petroleum from any other sourceintroduced through :line 6|.

Li a i sp cmc. of m 'invention'flsodium =alumlnumchlcride rrnayfbe suspended ahdlcr 'gidissolvedin alhytlrocarbongvhiclegsuch asvairnajrirow-a'cut,.tot straight' run'n htha Lboilingbfelow,

400 "12,; and; passed qcountercurrently'to' =a: streani' o! suitably iheated ethylene .i 'passing gupwardly through the Qtqwer as; iDue :tothe :disprs'ioh the c 'talyst' 1 lthe 'iliquidahydrocarbomi the esec- Itiveness'of the sodium aluminum chloride will- @be increased so as :to iincrease the amount oi polymerization :and hence thei productiori 1oz mo- =1tor lclflll. Generally, I'however, .the eflectiveness -"of this 1 catalyst is not r-sotimaterially ".increa'sedaas to :cause the .-.i'ormation aof can excess of zheavy polymers boiling above f the (gasoline rhoiling tpdint' "range 'which i may result when w aluminum chloride s-alonezismsed as'thetcatalyticsmaterial.

i1! iidesired, a catalyst to! the metallic rihalide type,\such asssodium aluminumrchlorlde,.:may be deposited i on arstatlonary -=granular.'-support, such -as minutes, and i011 so! :the character mentioned caused to silow over :it while uthe zheated ethylene ais1passedacountercurrently totthe ioiliover- 'the' wet :cata'lyst. The :,deposition i o! :catal-yst on aa granaular a-support .ior this :methodofioperation:.may

,be accomplished hy wetting -the support with 'a ;.solution to! :the catalyst in can "organic halide, such as aethylene vor propylene -.dlchloride, .and aevaporating"thasolvent. ilnacase'a similarlliquid is .used subsequently to promote the contact between the catalysttand the gas .toibeypolymerized, "the liquid-should begpreViously saturated-'withthe catalyst 1 in question to'tprevent solution; from the coated-support.

".The expression 'iiuicl :mixture appearing in the appended claimsiis in'ten'ded to-cover :the suspension .and/or solution -'oi' the catalyst .in the liquid vehicle.

While. If 'have described mylinventionfiin .detail with reference i to the preferred :manner :of operation, it is "to ibe clearly understood that my'invention is 'not limited in these respects except as appearing in 'the appended claims.

vIclaim: v 1. In the production or Jnormally liquid hydrocarbons Iirom normally gaseouskhydrocarbons containing unsaturated constituents, the rproeess that comprisesiintrodiicingsaid normallygaseous hydrocarbons in heated'conditioniinto=-a.,reaction zone for passage therethrough, aiintimately contacting said gaseous'hydrocarbons with a flcatalyst during the flow :thereoi' 'throug'hithereaction zone to effect polymerization thereoi into nor- ,mally liquid hydrocarbons 'containing @gasolin'e constituents :and 1heavier,- maintaining said .last- :mention'ed "hydrocarbons iin 'vaporous condition i inrsaid reaction zone. passing said *vapors :into a .i'ractionating zone to separate hydrocarbons in the ggasoline boiling range from heavier hydrocarbons, 11.18813118 847188; a part-.0! the-heavier 4 I amass-r hydrocarbons in heated condition into a reaction zone for passage therethrough, intimately contacting said gaseous hydrocarbons with a. catalyst during the flow thereof through the 'reaction zone to eflect polymerization thereof into normally'licb uid hydrocarbons containing gasoline constitucuts and heavier, maintaining said last-mentioned hydrocarbons in vaporous condition in said reaction zone, passing yapor s into a truetionating zone to separate hydrocarbons in the gasoline boiling range'trom heavier hydrocab' bone, separately withdrawing, unvaporized heavy mom v. A'rwmm. 

